Multi-stage supply chain management system with dynamic order placement

ABSTRACT

A global supply chain management system in an environment of multiple suppliers forming supply chains for one or more buyers connected over the Internet. The system includes a global processor with logic that maps “local” supply information for each buyer and each supplier, represented in one or more property tables having master information correlated to local information for each buyer and each supplier. The system manages processes from an input of lots to an output through supplier stages where clients each use fragmented different local information. A correlation means uses base lot indicators, one for each of the lots in common for all of said stages and executes supply chain management functions for tracking lots through the supplier stages and for dynamic creation of sets of purchase orders among groups of suppliers for processing the same lot through the supply chain.

COPYRIGHT NOTICE

[0001] A portion of the disclosure of this patent document containsmaterial which is subject to copyright protection. The copyright ownerhas no objection to the facsimile reproduction by any one of the patentdocument or the patent disclosure, as it appears in the Patent andTrademark Office patent file or records, but otherwise reserves allcopyright rights whatsoever.

BACKGROUND OF THE INVENTION

[0002] The present invention relates to internet commerce andparticularly to methods and apparatus that enable efficient managementof procurement transactions between buyers and suppliers in a supplychain that includes outsourcing with multiple suppliers.

[0003] Today, buyers and suppliers operate in a fast changing globalenvironment where quantities needed, pricing, technical specificationsand other supply parameters are frequently changing. The supply chainfor procurement of goods and services requires economies of scale,market pricing and rapid delivery. The management of the process ofprocuring goods and services is known as “supply chain management”.

[0004] Supply chain management is affected, for example, by theglobalization of businesses, the proliferation of product and servicevariety, the increasing complexity of supply networks, and theshortening of product life cycles. Market conditions are susceptible torapid demand fluctuation, inventory buildup, price competition, andfrequent specification changes. The supply chain for any particularcompany may be primarily internal supply. However, outsourcing is oftenused as an alternative to internal supply. By way of example,outsourcing is used to reduce costs, control inventories and respond torapid demand changes. Outsourcing increasingly is involving more andmore suppliers and supply chains are growing more complex.

[0005] In fast changing markets, buyers require “current” and at times“real-time” quotes and other information from suppliers that specify,among other things, accurate quantities, prices and delivery times. Theability to rapidly exchange information among buyers and suppliers isparamount to efficient supply chain management, particularly in anoutsourcing environment.

[0006] The Internet is an efficient electronic link among buyers andsuppliers for exchange of supply chain information. The Internetoperates with open standards and permits easy, universal and secureinformation exchange. Many roles exist for the Internet in commerce andsome of these roles have been described as “e-business”, “e-commerce”,and “internet commerce”. For purposes of the present specification, theterm “internet commerce” (or “i-commerce”) is used to represent the roleof the Internet in supply chain management.

[0007] “Internet commerce” enables companies, among other things, torealize greater efficiency, have better asset utilization, have fastertimes to market, reduce order fulfillment times, enhance customerservices and penetrate new markets. The Internet provides an enormouscapability for distribution of “current” information that is useful andnecessary for improved supply chain management. “Current” informationoften must be information available on a “real-time” or near “real time”basis. The Internet makes it possible to communicate “current”information about technology changes, availability of goods andservices, up-to-date prices for goods and services and other informationneeded to manage a supply chain. When outsourcing is employed in thesupply chain, the visibility into the current status of the supply chainis more difficult and requires new and improved methods for insuringthat complete, accurate and timely information is available. In theabsence of such current information, the ability to react in a timelyway to exceptions, abnormal events and other matters may be lost ordelayed. When the time for taking action is not recognized or isdelayed, supply chain management suffers and ultimately the cost ofgoods and services increases.

[0008] Although internet commerce simplifies many aspects ofprocurement, difficulties still exist and improvements are needed. Onedifficulty results because large numbers of suppliers and buyers areattached to the market place and each participant, whether buyer orsupplier, tends to use different parameters, terminology, terms,conditions and other information unique to the particular participant.These differences among participants result in an information exchangeproblem.

[0009] The information exchange problem is particularly acute, forexample, in the outsourcing semiconductor manufacturing industry becausegoods and services procured from one supplier are frequently furtherprocessed by other suppliers in subsequent downstream stages. In orderto have efficient and economical supply chain management, theinterrelationship among each buyer and the upstream and down streamsuppliers requires an exchange of “current” information that permitsreal-time visibility into the status of the supply chain, fastidentification of abnormal events and other information that permitsexception management.

[0010] One difficulty that frustrates the good visibility necessary forsupply chain management is the proliferation of different terminologyand specifications used by each participant in the supply chain. Whileany dominating buyer (and potentially any dominating supplier) candemand conformance with its way of doing business for its own business,the semiconductor manufacturing industry as a whole remains widelyfragmented without much progress toward standardization. Furthermore,this fragmentation is increasing rather than decreasing so that problemsare bound to exist for many years to come. The fragmentation exists, ofcourse, in many other industries.

[0011] Cooperative attempts have been made toward standardization insome industries. In the electronics component industry, the RosettaNethas the intent of providing industry wide standardization across theelectronic components trading network. Some attempts have been made tostandardize the semiconductor manufacturing industry. Notwithstandingthese attempts, the semiconductor manufacturing industry remainsfragmented and neither the RosettaNet nor any other standard has becomewidely adopted.

[0012] Accordingly, there is a great demand for improved supply chainmanagement methods and apparatus that will operate efficiently infragmented markets.

SUMMARY

[0013] The present invention is a global supply chain management systemin an environment of multiple suppliers forming supply chains for one ormore buyers connected over the Internet. The system includes a globalprocessor with logic that maps “local” supply information for each buyerand each supplier, represented in one or more property tables havingmaster information correlated to local information for each buyer andeach supplier. The system manages processes from an input of lots to anoutput through supplier stages where clients each use fragmenteddifferent local information. A correlation means uses base lotindicators, one for each of the lots, in common for all of said stagesand executes supply chain management functions for tracking lots throughthe supplier stages and for dynamic creation of sets of purchase ordersamong groups of suppliers for processing the same lot through the supplychain.

[0014] The environment is fragmented, that is, the industry as a wholehas not adopted any common set of standard terminology. In a fragmentedindustry, each instance of local supply information for any client(buyer or supplier) can be and usually is different from the localsupply information for any other client (buyer or supplier). Theembodiments of the present invention map supply information from and tothe master internal property information to and from fragmented outputlocal information according to the local property correlation for eachbuyer and each supplier. Notwithstanding the fragmentation among buyersand suppliers, the global supply chain management system functions toimplement global supply chain management using “current” supply chaininformation supplied over the Internet using the fragmented local supplyinformation used by the buyer or supplier.

[0015] To insure that the supply information is accurate, the globalprocessor executes data integrity processes to improve the reliabilityof the supply information. The data integrity processes include datachecking and data cleansing so that mapped supply information througherror detection and correction becomes more accurate than the originalfragmented raw data. Data integrity processes are performed, forexample, for data consistency within a record, data consistency within areport, data consistency across different reports from a particularsupplier, data consistency between suppliers' and buyers' data and dataconsistency among suppliers.

[0016] Based upon a continuously updated data base having “current”supply information, the global processor provides reports for numerousdata types including work-in-progress (WIP) reports, activity-basedtransaction reports (TR) that are created on a daily or other basis(including detail for each buyer and supplier stage), order reports,shipment reports and invoice reports. The terminology for the variousreports and the items reported upon have no standard definitions. Forexample, Orders are known by different names including purchase orders(PO) that logically are for goods and work orders (WO) that logicallyare for services. However, common practice in many industries uses theterm Purchase Order generically for any type of order whether for goodsor services. These reports are all conveniently distributed over theInternet in a format and with the terminology selected by each client,whether the client is a buyer or a supplier.

[0017] With access to “current” supply information for multiplesuppliers and with mapping capability among fragmented local propertytables of multiple suppliers and buyers, the global processor enablesthe Internet placement of purchase orders and work orders (POs and WOs)that can be accompanied by detailed specifications using electronicattachments.

[0018] With access to “current” supply information for multiplesuppliers and with mapping capability among fragmented local propertytables of multiple suppliers and buyers, the global processor enablesglobal planning from input to output of the supply chain. In thesemiconductor manufacturing supply chain, the planning extends fromWafer (front end, upstream) planning to package/test (back end, downstream) planning.

[0019] The supply chain management system is able to provide lottracking reports, actual cost lot detail reports, wafer rolling outputreports, finished goods rolling output reports, work in progressinventory reports and other reports useful for supply chain management.

[0020] The supply chain management system employs planning based uponupstream visibility in the supply chain. Such capabilities areparticularly useful in outsourcing to suppliers in a semiconductorsupply chain. In the semiconductor IC-design outsourcing industry, thebuyer (IC-design house) deals with multiple suppliers that providevarious outsourcing functions at different supplier stages. The buyerplaces a separate order (Purchase Order) with each supplier. Althoughthe Purchase Orders are separate between a buyer and each supplier, eachsupplier depends on the previous supplier (upstream supplier) in thesupply chain.

[0021] In the semiconductor manufacturing industry in order to procurefinished goods (for example a finished semicondcutor chip), a buyerfirst orders wafers from a Fab supplier (foundry); once the work at theFab supplier is finished, the buyer orders sorting from a Wafer Sortsupplier; after the Wafer Sort work is finished, the buyer ordersAssembly from an Assembly supplier; and finally, the buyer orders FinalTest from a Final Test supplier. The supply chain management system isable to perform group order generation for groups of dependent suppliers(such as Fab, Wafer Sort, Assembly and Final Test suppliers) in thesupply chain.

[0022] The supply chain management system performs alert processes basedupon alert conditions for specific events/reports/process of the supplychain. Alert reports are accessible to clients through i-commerceonscreen operations or through other methods of communication.Typically, alert conditions are communicated daily (or more frequentlyif desired) in the form of event generation and alert messages.

[0023] The input to the supply chain can take many forms and is afunction of the particular industry. The input can be raw materials,groups of components or “lots” of any kind. In the semiconductormanufacturing industry, frequently “lots” are “wafer lots” or “dielots”.

[0024] Lot Tracking is implemented by logic in the global processor tostore detailed information related to a lot in the supply chain. The lottracking information is categorized into two major parts, namely, staticdata where the data are fixed during the manufacturing processes anddynamic data where the data can be changed during the manufacturingprocesses. For example, the static data includes Date Code, Lot No,Order Date, Order Qty, Part No, Production Order No, PO No, Routing,Sup, and Unit Price. For example, the dynamic data includes two mainparts, namely, Date Information, {Completed Date, Hold Date, ReceivedDate, Ship Date, Start Date} and Quantity Information (Completed Qty,Downgrade Qty, Goodpart Qty, Hold Qty, Received Qty, Returned Qty,Scrappart Qty, Ship Qty, Start Qty}.

[0025] Lot tracking stores the genealogy of a lot in order to track andrecall the lot history quickly. This tracking is done by storing theparent-child relationship for lots. For flexible in loading the lottracking data, work-in-progress (WIP) reports and activity-basedtransaction reports (TR) are used.

[0026] Lot tracking is unique in the sense that a robust and consistentdata set for the production and finance related information of afragmented supply chain is maintained in one central place. Themaintenance of such information permits performance checking, such ascycle time, yield analysis and cost reporting on a lot basis down toeach stage of the supply chain.

[0027] The foregoing and other objects, features and advantages of theinvention will be apparent from the following detailed description inconjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0028]FIG. 1 depicts a plurality of supply chain management systemsorganized in part on an individual buyer basis and in an environment ofmultiple buyers and multiple suppliers forming a supply chain anddepicts a global supply chain management system for the multiple buyersand multiple suppliers.

[0029]FIG. 2 depicts further details of the global supply chainmanagement system of FIG. 1 with a multi-stage, multi-lot processor formultiple buyers and multiple suppliers.

[0030]FIG. 3 depicts details of the supply chain management system ofFIG. 1 and FIG. 2 with details for typical stages for processing.

[0031]FIG. 4 depicts details of a single one of the buyers and multiplesuppliers for the multistage, multi-lot processing within the supplychain management system of FIG. 1 and FIG. 2.

[0032]FIG. 5 depicts one example of a purchase order set for a lot inthe FIG. 4 system.

[0033]FIG. 6 depicts another example of a purchase order set for a lotin the FIG. 4 system.

[0034]FIG. 7 depicts another example of a purchase order set for a lotin the FIG. 4 system.

[0035]FIG. 8 depicts details of a multiple ones of the buyers andmultiple suppliers for the multistage, multi-lot processing within thesupply chain management system of FIG. 1.

[0036]FIG. 9 depicts a hardware block diagram of a computer systemnetwork for the supply chain management system of FIG. 1.

[0037]FIG. 10 depicts a software block diagram for the supply chainmanagement system of FIG. 1.

[0038]FIG. 11 depicts a correlation processor for correlating input andoutput information among clients including mapping and data integrityprocessing in the FIG. 9 and FIG. 10 systems for supply chainmanagement.

[0039]FIG. 12 depicts one example all of a multiple supplier branch in asupply chain transaction.

[0040]FIG. 13 depicts a cross supplier error checking in the example ofFIG. 12.

[0041]FIG. 14 depicts one example of a lot tracking report.

[0042]FIG. 15 depicts a cross supplier lot tracking example 1.

[0043]FIG. 16 depicts a cross supplier lot tracking example 2.

[0044]FIG. 17 depicts an actual cost—lot detail report.

[0045]FIG. 18 depicts the purchase order logic flow for creation andacceptance of blanket purchase orders and purchase orders.

[0046]FIG. 19 depicts an example of Final Test purchase order.

[0047]FIG. 20 depicts an example of an attachment that appears as athumbnail image in the Final Test purchase order of FIG. 19.

[0048]FIG. 21 depicts an example of a wafer rolling output report.

[0049]FIG. 22 depicts an example of a finished goods rolling outputreport with package planning.

[0050]FIG. 23 depicts an example of a work in progress inventory report.

DETAILED DESCRIPTION

[0051]FIG. 1 depicts a plurality of supply chain management systems 2-1,2-2, . . . , 2-M organized on an individual buyer (B) basis for thebuyers 3-1, 3-2, . . . , 3-B in an environment also including multiplesuppliers 7-1, 7-2, . . . , 7-S. FIG. 1 also depicts a supply chainmanagement system 1 serving all the multiple buyers 3-1, 3-2, . . . ,3-B and multiple suppliers 7-1, 7-2, . . . , 7-S. The multiple buyersand multiple suppliers of FIG. 1 are connected over the internet andhence are able to exchange supply information rapidly and essentially inreal time.

[0052] In FIG. 1, the local supply chain for each buyer includes supplystages 4 that typically include internal supply 5, that is, supply fromthe buyer's own organization, and outsourced supply 6, that is, supplyfrom external suppliers 7-1, 7-2, . . . , 7-S. Specifically, the buyers3-1, 3-2, . . . , 3-B have the supply stages 4-1, 4-2, . . . , 4-B, eachin turn having the internal supply 5-1, 5-2, . . . . 5-SS and theexternal supply 6-1, 6-2, . . . , 6-SS, respectively.

[0053] Each of the local supply chain management systems 2-1, 2-2, . . ., 2-M are maintained, for example, by the individual buyers 3-1, 3-2, .. . , 3-B and they are typically characterized as having their ownterminology, specifications and other supply chain parameters. In FIG.1, the suppliers and buyers as a whole are widely fragmented withoutmuch standardization. FIG. 1, therefore, as it encompasses local supplychain management systems 2-1, 2-2, . . . , 2-M is representative of thesemiconductor manufacturing industry.

[0054] Additionally, in FIG. 1, a global supply chain management system1 is designed to overcome the local fragmentation and efficiently serveall the multiple buyers 3-1, 3-2, . . . , 3-B and multiple suppliers7-1, 7-2, . . . , 7-S. The supply chain management system 1 includes a aglobal processor 8 that uses network communications such as the Internetfor overcoming the fragmentation of local supply chain managementsystems 2-1, 2-2, . . . , 2-M and for providing integrated supply chainmanagement. FIG. 2 depicts a supply chain management system operating inan environment of one or more buyers, B, including buyers B₀, B₁, . . ., B_(B) multiple suppliers, S, including suppliers S⁰, S₁, . . . , S_(S)in a supply chain. The buyers and suppliers are connected to aMulti-stage, Multi-Lot Processor for Multiple Buyers (B) and MultipleSuppliers (S) where the supply chain includes inputs I₀, I₁, . . . ,I_(I) to the supply chain and outputs O₀, O₁, . . . , O₀, . . . , O_(O)from the supply chain. The inputs are introduced to and the outputs arederived from Multiple Processing Stages (P) with Multiple Transactions(T) per Stage. The stages include [P_(0,0), P_(0,1), . . . , P_(0,N)];[P_(1,0), . . . ]; [ . . . , P_(m,n), . . .]; [P_(M,0), . . . ,P_(M,N)]. Each stage such as a typical stage P_(m,n) includes up to Ttransactions such as T₀, T₁, . . . , T₁, . . . , T_(T).

[0055]FIG. 3 depicts details of the supply chain management system ofFIG. 2 and details typical stages for processing. The one or morebuyers, B, including B₀, B₁, . . . , B_(b), . . . , B_(B), and themultiple suppliers, S, including S₀, S₁, . . . , S_(S), . . . , S_(S)are in the supply chain. Stages P_(m,n) and P_(m,n+1) are typical of themany stages [P_(0,0), P_(0,1), . . . , P_(0,N)]; [P_(1,0), . . .]; [ . .. ]; [P_(M,0), . . . , P_(M,N)] of FIG. 2. In particular, stage P_(m,n)includes up to T transactions such as T₀, T₁, . . . , T_(T). By way ofexample, stage P_(m,n) includes transactions (T₀), (T₁), (T₂), (T₃),(T₄), (T₅), . . . , (T_(T)) which are, for example, ORDER, WIP, YIELD,SHIPMENT, RECEIVE, WAREHOUSE, . . . , PAYMENT. Many other transactionsare possible, of course.

[0056] In FIG. 3, the stage P_(m,n) is in the supply chain with B_(b) asthe buyer and S_(S) as the supplier. By way of another example, thestage P_(m,n+1) is also in the supply chain with B_(b) as the buyer andS_(S) as the supplier. The stage P_(m,n+1) may include the transactions(T₀), (T₁), (T₂), (T₃), (T₄), (T₅), . . . , (T_(T)) which are forP_(m,n) ORDER, WIP, YIELD, SHIPMENT, RECEIVE, WAREHOUSE or stageP_(m,n+1) may have a different set of transactions.

[0057]FIG. 4 depicts details of a single one of the buyers and multiplesuppliers for the multistage, multi-lot processing within the supplychain management system of FIG. 2. FIG. 4 depicts a supply chainmanagement system operating in an environment of one buyer, B_(b) andmultiple suppliers, S, including S₀, S₁, S₂, S₃, S₄, S₅, . . . , S_(S)in a supply chain. The buyers and suppliers are connected to aMulti-stage, Multi-Lot Processor for Multiple Buyers (B) and MultipleSuppliers (S) where the supply chain includes inputs I₀, I_(I), I₂, . .. , I_(I) to the supply chain and outputs O₀, O₁, O₂, . . . , O_(O) fromthe supply chain. The inputs are introduced to and the outputs arederived from Multiple Processing Stages (P) with Multiple Transactions(T) per Stage. The stages include [P_(0,0), P_(0,1), P_(0,2),P_(0,3)];[P_(,0)P_(1,1), P_(1,2), P_(1,3)]; . . . ; [P_(x,0), P_(x,l),P_(x,2), P_(x,3)]; . . . ; [P_(M,0), . . . , P_(M,3)]. Each of thosestages includes a set of up to T transactions such as T₀, T₁, . . . ,T_(t), . . . , T_(T)like those described in connection wit FIG. 2.

[0058] In FIG. 4, buyer, B_(b) initiates operation of the supply chainin connection with a purchase by authorizing inputs I₁ and I₂. The I₁input, such as a semiconductor lot (wafer lot or die lot), to the supplychain progresses through a first sequence of stages [P_(0,0), P_(x,1),P_(1,2), P_(1,3)] to the output O₁. The supplier for the stage P_(0,0)stage is S₀, the supplier for the stage P_(x,1) stage is S₂, thesupplier for the stage P_(1,2) stage is S₃ and the supplier for thestages P_(1,3) stage is S₅. Similarly, the I₂ input, such as asemiconductor lot, to the supply chain progresses through a secondsequence of stages [P_(0,0), P_(0,1) P_(x,2), P_(x,3)] to the output O₂.The supplier for the stage P_(0,0) stage is S₀, the supplier for thestage P_(0,1) stage is S₁, the supplier for the stage P_(x,2) stage isS₄ and the supplier for the stages P_(x,3) stage is S_(S). FIG. 4depicts details of a single one of the buyers and multiple suppliers forthe multistage, multi-lot processing within the supply chain managementsystem of FIG. 1.

[0059]FIG. 5 depicts one example of a purchase order set for multistageprocessing in the FIG. 4 system. In FIG. 5, buyer, B_(b), initiatesoperation of the supply chain in connection with a purchase byauthorizing input I₁. The input I₁ to the supply chain progressesthrough a sequence of stages [P_(0,0), P_(x,1), P_(1,2), P_(1,3)] toprovide the output O₁. The supplier for the stage P_(0,0) stage is S₀,the supplier for the stage P_(x,1) stage is S₂, the supplier for thestage P_(1,2) stage is S₃ and the supplier for the stages P_(1,3) stageis S₅. In order for the work to be performed through the stages[P_(0,0), P_(x,1), P_(1,2), P_(1,3)] of FIG. 5, orders authorizing andspecifying the terms and conditions associated with the work are agreedupon by the buyer, B_(b), and the suppliers S₀, S₂, S₃, and S₅. Theorders in FIG. 5 are designated P_(0,0)S₀, P_(x,1)S₂, P_(1,2)S₃ andP_(1,3)S₅. These orders are called “purchase orders” or “work orders”and apply to goods and services. In some industries, both goods andservices are involved but in other industries either goods or servicesalone are involved.

[0060] In a semiconductor manufacturing environment, both goods andservices are involved. Typically, the I_(I) input is a lot (wafer lot ordie lot) and the processing stages are typically Fab, Wafer Sort,Assembly and Final Test. Other stages are of course possible andinclude, for example, Packaging (such as tape and real), Bumping andMarking. The processing stages Fab, Wafer Sort, Assembly and Final Testare each performed by a supplier and typically the different suppliersS₀, S₂, S₃, and S₅. The work at each of the processing stages of Fab,Wafer Sort, Assembly and Final Test is authorized and controlled by thepurchase orders P_(0,0)S₀, P_(x,1)S₂, P_(1,2)S₃ and P_(1,3)S₅,respectively. The output from the stages [P_(0,0), P_(x,1), P_(1,2),P_(1,3)] are represented by [G_(0,0), G_(x,1), G_(1,2), O₁]respectively. In FIG. 5, the set of purchase orders [P_(0,0)S₀,P_(x,)S₂, P_(1,2)S₃, P_(1,3)S₅] relate to interdependent work steps. Theoutput, O₁, is only obtained when all of the orders [P_(0,0)S₀,P_(x,1)S₂, P_(1,2)S₃, P_(1,3)S₅] have been executed according to theirterms and in sequence from the most upstream order P_(0,0)S₀ in turnthrough the orders P_(x,1)S₂, P_(1,2)S₃ to the most downstream orderP_(1,3)S₅. Furthermore, the downstream orders depend upon theperformance of the upstream orders. Typically, in the semiconductormanufacturing industry, the output at any stage is a variable, forexample, varying as to supply chain parameters such as quantity, qualityand delivery time. Accordingly, orders with downstream suppliers oftenneed to be conditioned upon the results of one or more upstreamsuppliers.

[0061] When information in a supply chain is not accurate and “current”,the entire supply chain can become inefficient, subject to distortionand unstable. One of the common distortion problems is escalatingover-requirement forecasts that tend to greatly exceed market demand.Such escalation is sometimes referred to as a “bullwhip” effect. The“bullwhip” results when each supplier in the supply chain over statesactual demand. The over demand escalates as forecasts are propagateddownstream in the supply chain. Each downstream supplier amplifies theover-requirement of the previous stage.

[0062] In the FIG. 5 purchase order set, each of the suppliers receives“current” and accurate information from upstream suppliers through useof communications over the Internet. The “current” information helps toreduce supply chain escalation of over requirements.

[0063]FIG. 6 depicts another example of a purchase order set formultistage processing in the FIG. 4 system. In FIG. 6, buyer, B_(b),initiates operation of the supply chain in connection with a purchase byauthorizing input I₂. The input I₂ to the supply chain progressesthrough a sequence of stages [P_(0,0), P_(0,1), P_(x,2), P_(x,3)] toprovide the output O₂. The supplier for the stage P_(0,0) stage is S₀,the supplier for the stage P_(0,1) stage is S₁, the supplier for thestage P_(x,2) stage is S₄ and the supplier for the stages P_(x,3) stageis S_(S). In order for the work to be performed through the stages[P_(0,0), P_(0,1), P_(x,2), P_(x,3)] of FIG. 6, orders authorizing andspecifying the terms and conditions associated with the work are agreedupon by the buyer, B_(b), and the suppliers S₀, S₁, S₄, and S_(S). Theorders in FIG. 6 are designated P_(0,0)S₀, P_(x,1)S₂, P_(1,2)S₃ andP_(1,3)S₅.

[0064] In a semiconductor manufacturing environment, the I₂ input is awafer lot and the processing stages are typically Fab, Wafer Sort,Assembly and Final Test each performed by a supplier and typically thedifferent suppliers S₀, S₁, S₄, and S_(S), respectively. The work ateach of the processing stages of Fab, Wafer Sort, Assembly and FinalTest is authorized and controlled by the orders P_(0,0)S₀, P_(0,1)S₁,P_(x,2)S₄ and P_(x,3)S_(S), respectively. The output from the stages[P_(0,0), P_(0,1), P_(x,2), P_(x,3)] are represented by [G_(0,0),G_(0,1), G_(x,2), O₂], respectively. In FIG. 6, the set of purchaseorders [P_(0,0)S₀, P_(0,1)S₁, P_(x,2)S₄, P_(x,3)S_(S)] relate tointerdependent work steps. The output, O₂, is only obtained when all ofthe orders [P_(0,0)S₀, P_(0,1)S₁, P_(x,2)S₄, P_(x,3)S_(S)] have beenexecuted according to their terms and in the sequence from the mostupstream order P_(0,0)S₀ in turn through the orders P_(0,1)S₁, P_(x,2)S₄to the most downstream order P_(x,3)S_(S).

[0065] In the FIG. 6 purchase order set, each of the suppliers receives“current” and accurate information from upstream suppliers through useof communications over the Internet. The “current” information helps toreduce supply chain escalation of over requirements.

[0066]FIG. 7 depicts another example of a purchase order set formultistage processing in the FIG. 4 system. In FIG. 7, buyer, B_(b),initiates operation of the supply chain in connection with a purchase byauthorizing input I₃. The input I₃ to the supply chain progressesthrough a sequence of stages commencing with a stage P_(0,0,) andthereafter split into two sequences, namely, [P_(x,1), P_(1,2), P_(1,3)]to provide the output O₃ and [P_(z+1,1), P_(0,2), P_(0,3)] to providethe output O₄. The supplier for the stage P_(0,0) stage is S₀, thesupplier for the stage P_(x,1) stage is S₂, the supplier for the stageP_(1,2) stage is S₃ and the supplier for the stages P_(1,3) stage is S₅and the supplier for the stage P_(x+1,1) stage is S₆, the supplier forthe stage P_(0,2) stage is S₇ and the supplier for the stages P_(0,3)stage is S₈. In order for the work to be performed through the stageP_(0,0) an order authorizing and specifying the terms and conditionsassociated with the work are agreed upon by the buyer, B_(b), and thesupplier S₀. In order for the work to be performed through the stages[P_(x,1), P_(1,2), P_(1,3)] of FIG. 7, orders authorizing and specifyingthe terms and conditions associated with the work are agreed upon by thebuyer, B_(b), and the suppliers S₂, S₃ and S₅. In order for the work tobe performed through the stages [P_(x+1,1), P_(0,2), P_(0,3)] of FIG. 7,orders authorizing and specifying the terms and conditions associatedwith the work are agreed upon by the buyer, B_(b), and the suppliers S₆,S₇ and S₈. The orders in FIG. 7 are designated [PO_(0,0),S₀],[PO_(x,1)S₂, PO_(1,2)S₃, PO_(1,3)S₅] and [PO_(x+1,1)S₆, PO_(0,2)S₇,PO_(0,3)S_(8]).

[0067] In a semiconductor manufacturing environment, the I₃ input is awafer lot and the processing stages are typically Fab, Wafer Sort,Assembly and Final Test each performed by a supplier and typically thedifferent suppliers [S₀], [S₂ and S₆], [S₃ and S₇] and [S₅ and S₈],respectively. The work at each of the processing stages of Fab, WaferSort, Assembly and Final Test is authorized and controlled by the orders[PO_(0,0)S₀], [PO_(x,1)S₂, PO_(0,2)S₃, PO_(1,3)S₅] and [PO_(z+1,1)S₆,PO_(0,2)S₇, PO_(0,3)S₈]. The output from the stage P_(0,0) is split andis represented by [₁G_(0,0) and ₂G_(0,0)]. The outputs from the stages[P_(x,1), P_(1,2), P_(1,3)] are represented by [G_(x,1), G_(1,2), O₃],respectively. The outputs from the stages [P_(x+1,1), P_(0,2), P_(0,3)]are represented by [G_(x+1,1), G_(0,2), O₄], respectively.

[0068] In FIG. 7, the sets of purchase orders [PO_(0,0)S₀], [PO_(x,1)S₂,PO_(1,2)S₃, PO_(1,3)S₅] and [PO_(x+1,1)S₆, PO_(0,2)S₇, PO_(0,3)S₈]relate to interdependent work steps. The output, O₃, is only obtainedwhen all of the orders [PO_(0,0)S₀] and [PO_(x,1)S₂, PO_(1,2)S₃,PO_(1,3)S₅] have been executed according to their terms and in thesequence from the most upstream order to the most downstream order. Theoutput, O₄, is only obtained when all of the orders [PO_(0,0)S₀] and[PO_(x+1,1)S₆, PO_(0,2)S₇, PO_(0,3)S₈] have been executed according totheir terms and in the sequence from the most upstream order to the mostdownstream order. Further each of the subset order sequences[PO_(x,1)S₂, PO_(1,2)S₃, PO_(1,3)S₅] and [PO_(x+1,1)S₆,PO_(0,2)S₇,PO_(0,3)S₈] are interdependent in that they both drive from the parentorder [PO_(0,0)S₀].

[0069] In the FIG. 7 purchase order set, each of the suppliers receives“current” and accurate information from upstream suppliers through useof communications over the Internet. The “current” information helps toreduce supply chain escalation of over requirements. The FIG. 7sequences indicate the complexity that arises among suppliers in amultistage supply chain typical of outsourcing in the semiconductormanufacturing industry when only a single buyer, B_(b)is considered.

[0070]FIG. 8 depicts a supply chain management system 1 operating in anenvironment of multiple buyers (B) 3 including buyers (B₀, B_(I), . . ., B_(b), . . . , B_(B)) 3-1,3-2, . . . 3-b, . . . , 3-B and multiplesuppliers (S)7 including suppliers (S₀, S₁, . . . , S_(S)) 7-1,7-2, . .. , 7S in a supply chain. The buyers 3 and suppliers 7 are connected toa multi-stage, multi-lot processor 8′ that is one embodiment of theglobal processor 8 of FIG. 1. In FIG. 8, the buyer B_(b)is typical ofall the buyers B₀, B_(I), . . . , B_(b), B_(B)and buyer B_(b)placesorders and receives goods and services from a multistage supply chainP{B_(b)} 4-b. The multistage supply chain P{B_(b)} is like any of themultistage supply chains described in connection with FIG. 1 throughFIG. 7. For the semiconductor manufacturing industry, the multistagesupply chain P {B_(b)} includes a plurality of stages P_(bx) organizedfunctionally, for example, into Fab, Wafer Sort, Assembly and Final Teststages. The stages P_(bx) are like any of the stages described inconnection with FIG. 1 through FIG. 7. The single buyer B_(b)is typicaland more generally all the buyers B₀, B_(I), . . . , B_(b), . . . ,B_(B)are associated with multistage supply chains P{B₀}, P{B_(I)}, . . ., P{B_(b)}, . . . , P{B_(B)}, respectively. The stages P_(bx) for anyparticular one of the supply chains P{B₀}, P{B₁}, P{B_(b)}, . . . ,P{B_(B)} maybe same as or different from the stages P_(bx) for any otherones of the supply chains P{B₀}, P{B_(I)}, . . . , P{B_(b)}, . . . ,P{B_(B)}. FIG. 8 indicates the great complexity of the supply chainenvironment for multiple buyers and multiple suppliers common in manyindustries such as the semiconductor manufacturing industry.

[0071]FIG. 9 depicts a hardware block diagram of a computer systemnetwork for the supply chain management system of FIG. 1. In FIG. 9, theCLIENT(BUYER/SUPPLIER) 91-1, the CLIENT(BUYER/SUPPLIER) 91-2 and theCLIENT(BUYER/SUPPLIER) 91-C connect over INTERNET 99 to MULTI-STAGE,MULTI-LOT PROCESSOR 8 and particularly to the SWITCH 92. The SWITCH 92functions to switch incoming and outgoing traffic between the LOADBALANCER 93-1 and the LOAD BALANCER 93-2. The LOAD BALANCER 93-1 and theLOAD BALANCER 93-2 connect between the SWITCH 94-1 and the SWITCH 94-2.The SWITCH 94-1 and the SWITCH 94-2 connect to the APPLICATION SERVER95-1 and the APPLICATION SERVER 95-2. The APPLICATION SERVER 95-1 andthe APPLICATION SERVER 95-2 execute programs for performing supply chainmanagement in the multiple buyer, multiple supplier environment. TheAPPLICATION SERVER 95-1 and the APPLICATION SERVER 95-2 connect throughDATA SERVER 96-1 and DATA SERVER 96-2 to the DISK ARRAY 97 whichincludes the disks MAIL 97-1, DATABASE 97-2 and LOG-IN 97-3. Theprocessor 8 of FIG. 9 includes two-way redundancy for providing highlyreliable and highly available supply chain management services to thebuyers and suppliers that are the clients in the network.

[0072]FIG. 10 depicts a software block diagram for the supply chainmanagement system of FIG. 1. In FIG. 9, the CLIENT (BUYER/SUPPLIER)91-1, the CLIENT (BUYER/SUPPLIER) 91-2 and the CLIENT (BUYER/SUPPLIER)91-C connect over INTERNET 99 to MULTI-STAGE, MULTI-LOT PROCESSOR 8 andparticularly to the SECURITY/SWITCH 92′. The SECURITY/SWITCH 92′functions to perform security checks on the internet traffic and toswitch incoming and outgoing traffic between the WEB 98-1 and theBUSINESS LOGIC 98-2 executing in the PROCESS SERVERS 95′. The WEB 98-1and the BUSINESS LOGIC 98-2 and the APPLICATION SERVER 95-2 connect tothe DATA SERVER 97′ which includes MAIL 97′-1, DATABASE 97′-2 and LOG-IN97-3 functions. The WEB 98-1 process functions are primarily forreal-time interactive communications between the DATA SERVER 97′ andCLIENTs 91-1, 91-2, . . . 91-C. The BUSINESS LOGIC 98-2 is primarily forperforming the operations necessary for supply chain management servicesin the multiple buyer, multiple supplier environment. The BUSINESS LOGIC98-2 is logic means for accessing master information for executingsupply chain management functions for the clients to provide managementdata.

[0073]FIG. 11 depicts a CORRELATION PROCESSOR 98′-2 for correlatinginput and output information among clients. The correlation is among thelocal and fragmented information that is different for each client. Inthe particular embodiment of FIG. 11, the CORRELATION PROCESSOR 98′-2performs mapping and data integrity processing in connection with thesupply chain management. In FIG. 11, the CLIENTs 91-1, 91-2, . . . ,91-C connect over INTERNET 99 to the CORRELATION PROCESSOR 98′-2. TheCORRELATION PROCESSOR 98′-2 is part of the BUSINESS LOGIC 98-2 of FIG.10. The MESSAGE FILE CONNECTOR 88-1 functions using conventionalinternet protocols (httpRobot, ftpRobot, ftpServer) for incoming andoutgoing communications over the INTERNET 99. The FILE MONITOR 88-2detects the file format and makes conventional conversion to commaseparated values (for example, flat2csv, xls2csv). The CONVERTER 88-3converts the csv values to an xml format as an input to the INPUT MAPPER88-4. The INPUT MAPPER 88-4 functions to map the local property valuesinherent in the input data to master property values defined by thesupply chain management system. The INPUT MAPPER 88-4 accesses thePROPERTY TABLES in the DATABASE 97′-2 to do the mapping. After mapping,the mapped raw input data is converted in CONVERTER 88-5 from an xmlformat to a database format (xml TO db) and stored in the RAW DATA store88-7 ₁. The mapped raw input data is then processed in the DATAINTEGRITY UNIT 88-6 including the Data Checking unit 88-6 ₁ and the DataCleansing 88-6 ₂. The checked and cleaned processed input data is storedThe checked and cleaned raw data is processed in the PROCESS DATA UNIT98 and the processed data is stored in the PROCESSED DATA store 88-7 ₂.Any of the raw data in the RAW DATA store 88-7 ₁ or the processed datain the PROCESSED DATA store 88-7 ₂ can be communicated to the CLIENTs91-1, 91-2 and 91-C using the OUTPUT MAPPER 88-8 to map the output datato the form expected by the client. The OUTPUT MAPPER 88-8 functions tomap the master property information defined by the supply chainmanagement system to the local property information of the type and formused by clients as revealed in the input data from clients. The OUTPUTMAPPER 88-8 is an output mapping means for mapping management data tolocal data for clients. The OUTPUT MAPPER 88-8 accesses the PROPERTYTABLES in the DATABASE 97′-2 to do the mapping.

[0074] Different buyers, such as Fabless semiconductor companies,frequently require different information from their suppliers' daily orother reports. Often suppliers can provide only one format for thesereports to all of their buyers due to the constraints in their computersystems. To bridge this information gap, the supply chain managementsystem uses a database schema which provides a master property tableholding a super set of information for all the clients (buyers andsuppliers) using the system. When the buyers and suppliers send theirrecords, reports and inquiries to the supply chain management system,the data are mapped into the master database schema.

[0075] A client-specific property file is created to describe theclient-specific (“local”) data for each client. In one embodiment,MicroSoft BizTalk is used to generate a schema.biz and mapper.biz todefine the mapping between a client's local data and the master databaseschema. Then, a JAVA class, CSV2XML, is applied to convert these datareports from .DBF, .XLS or .CSV format into XML format files based onthe description in the corresponding local property files. The XML stylesheet file, .XSL, generated by the mapper.biz and the JAVA class,XML2DB, are used to convert the report data into the final format to beimported into the master table of the database.

[0076] The master table can be in any form including indexed files,linked sub-tables, linked lists, among others. The following TABLE 1 isan example of a master property table where the column “Field Name”represents the master table name and the column “Description” brieflydescribes the general use of the Field Name. TABLE 1 is representativeof a master table and is not intended to be exhaustive. Other fields areadded as the need arises. TABLE 1 Copyright 2002 GetSilicon, Inc. FieldName Description 1 Actual Charge Charge for Units actually delivered asFinal Product 2 Actual Qty Quantity of Units actually delivered as FinalProduct 3 Back Issue Die Qty Back Issued Die Qty 4 Base Lot Indicatornumber derived from the lot genealogy specification 5 Bin Physical binlocation 6 Completed Date Date on which the manufacturing processcompletes 7 Completed Die Qty Number of dies completed in the processing8 Completed Qty Number of Units completed in the processing 9 CompletedWafer Qty Number of wafers completed in the processing 10 Date Code Codeto designate the manufacturing date of product 11 DescriptionDescription of process parameters 12 Device Type Type of device 13 DownGrade Qty Number of Units being downgraded to lower specs afterproduction 14 Est Amount Estimated finished goods amount 15 Est_FG_DateEstimated finished goods date 16 Est_FG_Qty Estimated finished goodsquantity 17 Estimate Complete Date Revised completion date based on thecurrent process information 18 ETA Date Date of estimated time ofarrival 19 Good Unit Qty Number of good Units 20 Gross Ship Weight Grossweight as shipped 21 Hold Date Date Hold starts 22 Hold Qty Number ofUnits on hold 23 I_No Identification number for product 24 Invoice DateInvoice created date 25 Invoice No Invoice number 26 Lot No Number forClient derived from Base Lot indicator 27 Net Shipping Weight Net weightas shipped 28 Notes Special instructions and details 29 Order ConfirmDate Date order confirmed 30 Order Date Date on which the productionorder is issued 31 Order Qty Quantity ordered 32 Order Req Date Dateorder requested 33 Ordered Die Qty Ordered die qty 34 Ordered Wafer QtyOrdered wafer qty 35 Part No Part number 36 PO No Purchase Order number37 PO Rev No Revolution of PO No 38 Process Name of detailed processused by Supplier 39 Production Order No Number for production order 40Received Date Date on which Units are received 41 Received Die QtyNumber of die received for the manufacturing process 42 Received QtyNumber of Units received 43 Received Wafer Qty Number of wafer receivedfor the manufacturing process 44 Return Code Code used to make a return45 Return Order No Number used to make a return 45 Return Qty Number ofUnits returned 46 Routing Name of stage, such as Fab, Wafer Sort,Assembly, Final Test 47 Routing Status Status such as scheduled,started, active, hold, completed or shipped 48 Scrap Qty Number of Unitsbeing scraped 49 Return Qty Number of Units being returned 50 Ship CostShipping cost 51 Ship Date Date of current shipment 52 Ship Qty Unitquantity in the current shipment 53 Ship Dimension Dimension of packedshipment 54 Ship Line No Number on shipping package 55 Ship ToDestination client 56 Ship Via Carrier name 57 Shipping Notice No Numberon shipping package 58 Start Date Date on which the processing begins 59Start Qty Number of Units when the processing starts 60 Sup Suppliername 61 Topmark Topmark visible on top of finished goods 62 Unit Unittype such as Wafer, Die 63 Unit Price Unit price per Unit 64 WeightedCompleted Date Weighted completed date, based on the quantity 65Weighted Received Date Weighted received date, based on the quantity 66Weighted Ship Date Weighted ship date, based on the quantity 67 WeightedStart Date Weighted start date, based on the quantity 68 WIP Die QtyNumber of dies that is active in the production process 69 WIP Wafer QtyNumber of wafers that is active in the production process 70 WO No WorkOrder No 71 WO Rev No Work Order Rev 72 Yield Output over input (inpercent)

[0077] The following TABLE 2, TABLE 3 and TABLE 4 are examples of themaster property table and the corresponding local client informationmapping. In TABLE 2, the column “Field Name” represents the master tableinformation, the column “Buyer1” represents a buyer client local clientinformation of a buyer and the columns “Fab1”, “Wafer Sort1”,“Assembly1” and “Test1” represent local client information of foursuppliers representing different stages of semiconductor manufacturing.

[0078] In TABLE 3, the column “Field Name” represents the master tableinformation, the column “Buyer1” represents local client information ofa buyer and the columns “Wafer Sort1” and “Wafer Sort2” represent localclient information of two suppliers representing the same Wafer Sortstage of semiconductor manufacturing.

[0079] In TABLE 4, the column “Field Name” represents the master tableinformation, the column “Buyer1” represents a buyer client local clientinformation of a buyer and the columns “Assembly1”, “Assembly2” and“Assembly3” represent local client information of two suppliersrepresenting the same Assembly stage of semiconductor manufacturing.Certain ones of the fields in TABLE 1 derive directly from client fieldswhile others are derived as a result of processing.

[0080] Examples of derived fields include:

[0081] 1) Base Lot. A derived number indicator used for tracking the lotgenealogy for a buyer through all suppliers.

[0082] 2) In-Date. A derived date that is the earliest date associatedwith any transaction at a client, for example, the earlier of theReceived Date and the Start Date.

[0083] 3) Out-Date. The latest date associated with any transaction at aclient, for example, the later of the Complete Date and the Ship Date.

[0084] 4) The term Qty generally means quantities that have beenaccumulated to show totals for one or more transactions or parts of atransaction.

[0085] 5) The term Weighted refers to dates weighted by quantity. Forexample, for 100 pcs received on Jun. 5, 2002 0:0:0 and 200 pcs receivedon Jun. 6, 2002 0:0:0, the Weighed Received Date is:(date1*qty1+date2*qty2)/(qty1+qty2), the Weighted Received Date is: Jun.5, 2002 18:0:0.

[0086] 6) Est_FG_Date. The estimated finished good date, the date whichthe current material will be available as finished goods. TheEst_FG_Date is calculated based on the standard cycle time of each stage(routing).

[0087] 7) Est_FG_Qty. The estimated finish good quantity, the expectedquantity which the current material becomes the final finish goods. TheEst_FG_Qty is calculated based on the expected Yield of each stage.

[0088] 8) Yield. Determined as the ratio Output Qty/Input Qty.

[0089] The derived fields are only by way of example as any number ofadditional derived fields may be added as the need arises. TABLE 2 #Field Name Buyer1 Fab1 Wafer Sort1 Assembly1 Test1 1 Shipping NoticePackageNO Invoice Number Reference_No Packing No Reference No No 2 PO NoCustomer PO 3 PO Rev No 4 WO No Work Order No Work Order WO Number Po NoNo 5 WO Rev No Work Order Rev 6 Order Line No Order Line No 7 DeviceType Device 8 Part No Part Num Part No. Part Num Part No 9 I_No I_NoCustomer Product No Device 10 Bin BIN BIN 11 Lot No CM Lot No Fab1 LotID Lot No. Lot No Lot No 12 Description 13 Order Date 14 Order Qty 15Order Req Date 16 Order Confirm Date 17 UM 18 Ship Line No Package NOItem N 19 Ship Date PACKAGE Date Date Date Date 20 ETA Date 21 ShipWafer Qty Qty Ship Qty Wafer QTY Qty1 Shipping QTY 22 Ship Die Qty GoodDie Qty QTY Qty2 23 Ship To Ship To Ship to To Location 24 Ship Via VIAvia 25 Gross Ship Weight G.W 26 Net Shipping N.W Weight 27 ShipDimension Dimension 28 Ship Cost 29 Invoice Date invoice created dateinvoice date inv date 30 Invoice No Invoice No Invoice No Invoice NoInvoice No Invoice No 31 Notes 32 Date code Date Code 33 Return Order No34 Return Code

[0090] TABLE 3 # Field Name Buyer1 Wafer Sort1 Wafer Sort2 1 ShippingNotice No Package NO Reference_No F_SHIP_NO 2 PO No 3 PO Rev No 4 WO NoWork Order No Work Order No F_RELEASE_NO 5 WO Rev No Work Order Rev 6Order Line No F_RELEASE_NO 7 Device Type Device Wafer 8 Part No Part NumPart No. F_CUST_PN 9 I_No I_NO 10 Bin BIN 11 Lot No CM Lot No Lot No.F_CUST_LOT_NO 12 Description 13 Order Date 14 Order Qty 15 Order ReqDate 16 Order Confirm Date 17 Unit 18 Ship Line No Package NO 19 ShipDate PACKAGE Date Date F_MODIFY_DATE 20 ETA Date 21 Ship Wafer Qty QtyWafer Shipping QTY F_PIECES 22 Ship Die Qty Good Die Qty F_GOOD_DIES 23Ship To F_SHIP_TO 24 Ship Via 25 Gross Ship Weight 26 Net ShippingWeight 27 Ship Dimension 28 Ship Cost 29 Invoice Date invoice createddate 30 Invoice No Invoice No Invoice No Invoice No 31 Notes 32 Datecode 33 Return Order No 34 Return Code

[0091] TABLE 4 # Field Name Assembly1 Assembly2 Assembly3 1 ShippingNotice No Package NO Packing No SHIPMENT NO 2 PO No 3 PO Rev No 4 WO NoWO Num WO Number P.O. NUM 5 WO Rev No WO Rev Num 6 Order Line No OrderLine No 7 Device Type Device Type Device DEVICE 8 Part No Part No PartNum 9 I_No 10 Bin 11 Lot No Lot No Lot No LOT NUM 12 Description 13Order Date 14 Order Qty Qty 15 Order Req Date 16 Order Confirm Date 17Unit 18 Ship Line No Item 19 Ship Date ETA Date ETD 20 ETA Date ETD ETA21 Ship Wafer Qty QTY 22 Ship Die Qty QTY QTY 23 Ship To Ship to LocShip to Location 24 Ship Via VIA VIA FORWARDER 25 Gross Ship Weight G.WG.W WEIGHT 26 Net Shipping Weight N.W N.W 27 Ship Dimension Dimension 28Ship Cost 29 Invoice Date 30 Invoice No Invoice Date invoice date 31Notes Invoice No Invoice No Invoice No 32 Date code 33 Return Order No34 Return Code

[0092] One program for implementing the mapping described is presentedin the following TABLE 5. TABLE 5 Copyright 2002 GetSilicon, Inc.<xsl:stylesheet xmlns:xsl=‘http://www.w3.org/1999/XSL/Transform’ xmlns:msxsl=‘urn:schemas-microsoft-com:xslt’xmlns:var=‘urn:var’ xmlns:user=‘urn:user’ exclude-result-prefixes=‘msxslvar user’ version=‘1.0’> <xsl:output method=‘xml’ encoding=‘UTF-8’indent=‘yes’ omit-xml-declaration=‘yes’/> <xsl:template match=‘/’><xsl:apply-templates select=‘INSERT’/> </xsl:template> <xsl:templatematch=‘INSERT’> <INSERT> <xsl:for-each select=‘ROWSET_shipHEADER’><ROWSET_SHIPHEADER> <xsl:for-each select=‘ROW_shipHEADER’><ROW_SHIPHEADER> <!−− Connection from source node “ToID” to destinationnode “BUYER” −−> <BUYER><xsl:value-of select=‘ToID/text( )’/></BUYER><!−− Connection from source node “FromID” to destination node “SUPPLIER”−−> <SUPPLIER><xsl:value-of select=‘FromID/text( )’/></SUPPLIER> <!−−Connection from source node “reportDate” to destination node“REPORTDATE” −−> <REPORTDATE><xsl:value-of select=‘reportDate/text()’/></REPORTDATE> <!−− Connection from source node “tDate” todestination node “TDATE” −−> <TDATE><xsl:value-of select=‘tDate/text()’/></TDATE> <!−− Connection from source node “fileName” to destinationnode “FILENAME” −−> <FILENAME><xsl:value-of select=‘fileName/text()’/></FILENAME> <!−− Connection from source node “fileSize” todestination node “FILESIZE” −−> <FILESIZE><xsl:value-ofselect=‘fileSize/text( )’/></FILESIZE> <!−− Connection from source node“RecordSize” to destination node “RECORDSIZE” −−><RECORDSIZE><xsl:value-of select=‘ancestor::*[2]/RecordSize/text()’/></RECORDSIZE> <!−− Connection from source node “ROW_shipHEADER” todestination node “ROW_SHIPHEADER” −−> <xsl:value-of select=‘./text( )’></ROW_SHIPHEADER> </xsl:for-each> <!−− Connection from source node“ROWSET_shipHEADER” to destination node “ROWSET_SHIPHEADER” −−><xsl:value-of select=‘./text( )’/> </ROWSET_SHIPHEADER> </xsl:for-each><xsl:for-each select=‘shipITEM’> <SHIPITEM> <xsl:for-eachselect=‘ROWSET_ship1’> <ROWSET_SHIP1> <xsl:for-each select=‘ROW_ship1’><ROW_SHIP1> <!−− Connection from source node “LineNumber” to destinationnode “LINENUMBER” −−> <LINENUMBER><xsl:value-of select=‘LineNumber/text()’/></LINENUMBER> <!−− Connection from source node “PO_NO” todestination node “ORDERNO” −−> <ORDERNO><xsl:value-ofselect=‘PO_NO/text( )’/></ORDERNO> <!−− Connection from source node“SHP_PRD_NO” to destination node “PARTNO” −−> <PARTNO><xsl:value-ofselect=‘SHP_PRD_NO/text( )’/></PARTNO> <!−− Connection from source node“ORD_QTY” to destination node “ORDERQTY” −−> <ORDERQTY><xsl:value-ofselect=‘ORD_QTY/text( )’/></ORDERQTY> <!−− Connection from source node“REQ_DATE” to destination node “ORDERREQDATE” −−><ORDERREQDATE><xsl:value-of select=‘REQ_DATE/text( )’/></ORDERREQDATE><!−− Connection from source node “SHIP_DATE” to destination node“SHIPDATE” −−> <SHIPDATE><xsl:value-of select=‘SHIP_DATE/text()’/></SHIPDATE> <!−− Connection from source node “SHIP_QTY” todestination node “WAFERQTY” −−> <WAFERQTY><xsl:value-ofselect=‘SHIP_QTY/text( )’/><WAFERQTY> <!−− Connection from source node“LAST_DATE” to destination node “INVOICEDATE” −−><INVOICEDATE><xsl:value-of select=‘LAST_DATE/text( )’/></INVOICEDATE><!−− Connection from source node “SO_NO” to destination node “INVOICENO”−−> <INVOICENO><xsl:value-of select=‘SO_NO/text( )’/></INVOICENO> <!--Connection from source node “REMARK” to destination node “NOTES” −−><NOTES><xsl:value-of select=‘REMARK/text( )’></NOTES> <!−− Connectionfrom source node “ROW_ship1” to destination node “ROW_SHIP1” −−><xsl:value-of select=‘./text( )’/> </ROW_SHIP1> </xsl:for-each> <!−−Connection from source node “ROWSET_ship1” to destination node“ROWSET_SHIP1” −−> <xsl:value-of select=‘./text( )’/> </ROWSET_SHIP1></xsl:for-each> <xsl:for-each select=‘ROWSET_shipMEMOS’><ROWSET_SHIPMEMOS> <xsl:for-each select=‘ROW_shipMEMOS’> <ROW_SHIPMEMOS><!−− Connection from source node “MEMONAME” to destination node“MEMONAME” −−> <MEMONAME><xsl:value-of select=‘MEMONAME/text()’/><MEMONAME> <!−− Connection from source node “MEMO” to destinationnode “MEMO” −−> <MEMO><xsl:value-of select=‘MEMO/text( )’></MEMO> <!−−Connection from source node “ROW_shipMEMOS” to destination node“ROW_SHIPMEMOS” −−> <xsl:value-of select=‘./text( )’/> <ROW_SHIPMEMOS><xsl:for-each> <!−− Connection from source node “ROWSET_shipMEMOS” todestination node “ROWSET_SHIPMEMOS” −−> <xsl:value-of select=‘./text()’/> </ROWSET_SHIPMEMOS> </xsl:for-each> <!−− Connection from sourcenode “shipITEM” to destination node “SHIPITEM” −−> <xsl:value-ofselect=‘./text( )’/> </SHIPITEM> </xsl:for-each> </INSERT></xsl:template> </xsl:stylesheet>

[0093] After the input data has been mapped and stored as raw data asdescribed above and in connection with TABLE 2, TABLE 3, TABLE 4 andTABLE 5, the mapped raw input data is then processed in the DATAINTEGRITY UNIT 88-6 including the Data Checking unit 88-6, and the DataCleansing 88-6 ₂ to improve the quality of the raw data.

[0094] One of the significant barriers to efficient supply chainmanagement is poor data quality. A large amount of the data is providedby suppliers for Fabless semiconductor buyers. The buyers and suppliers(together clients of the supply chain management system) are connectedin common over the Internet and the suppliers supply local supplierinformation to said system via electronic records and reports. A recordis a single entry at one time and reports reflect accumulated data froma number of records or other reports. The data integrity unit of FIG. 11operates to process the raw data to obtain clean processed data. Theclean processed data is checked for consistency with buyer's originallocal information as well as the local information provided by all theother suppliers in the supply chain.

[0095] The data integrity processing is divided into five parts:

[0096] Part 1. Data Consistency Within a Record.

[0097] Part 2. Data Consistency Within a Report.

[0098] Part 3. Data Consistency Across Different Reports from aParticular Supplier.

[0099] Part 4. Data Consistency Between Supplier and Buyer Data.

[0100] Part 5. Data Consistency Between Suppliers.

[0101] In connection with the different parts, the data relates to WIP(Work In Progress) Reports, activity-based Transaction Reports (TR)including Daily Transaction Reports (DTR), Orders including PurchaseOrders (PO) and Work Orders (WO), Shipment Reports and Invoices.

[0102] For each of Part 1 to Part 5, cleansing is performed for StaticData Consistency and for Dynamic Data Consistency. By way of example,for Static Data Consistency, in a PO, the Lot No, and Part No arechecked for consistency. By way of example, for Dynamic DataConsistency, Date Sequence, Quantity Sequence and Routing Sequence arechecked.

[0103] In connection with Part 1, Data Consistency Within a Record,typically the following are checked:

[0104] 1. Required Field Missing.

[0105] 2. Date Sequence Check. For example, the sequence ordereddate<=received date<=start date<=completed date<=shipped date is checkedwhere “<=” means “is earlier than”.

[0106] 3. Quantity Sequence Check. For example, the sequence receivedqty>start qty≧completedqty≧shippedqty is checked where “≧” means “isgreater than or equal to”.

[0107] 4. Date out of Reasonable Range. For example, (current date−startdate) is too large and estimated completion date is before the currentdate.

[0108] 5. Quantity out of Reasonable Range. For example, scrap ordowngrade quantity too big.

[0109] 6. Status of a Lot Inconsistent with WIP Quantity.

[0110] 7. Data Dictionary Check. Key data is included andcross-referenced. For example, device is not found in device mastertable, item number is not found in item master table, WIP status keyword is not conformed to the pre-defined specification. A masterdictionary for each type of data is stored in the master table to enablechecking to be performed.

[0111] As an example in connection with Part 2, Data Consistency Withina Report, the following are checked:

[0112] 1. Duplicated Data Check. For example, the same lot appears inmore than one record in a WIP or the same transaction appears twice in aDTR.

[0113] 2. Date Sequence Error. For example, complete-out beforereceive-in transaction in DTR.

[0114] 3. Status Sequence Error. For example, status sequence should be:(scheduled)<(active or hold)<(completed or closed)<(ship or closed)where “<” means prior to.

[0115] As an example in connection with Part 3, Data Consistency AcrossDifferent Reports from a Particular Supplier, the following are checked:

[0116] 1. Data Content Inconsistency. For example, device or item has nochanges for the same lot at a different date.

[0117] 2. Quantity Inconsistency. For example, total quantity(WIP+scrap+warehouse) changes for the same lot on a different date.

[0118] 3. Date Inconsistency. For example, start date or completion datechanges for the same lot.

[0119] 4. WIP Movement Error. For example, a lot has been completed thenmoves back to WIP.

[0120] 5. Status Sequence Error. For example, a lot moves to completebefore becomes active.

[0121] 6. Abnormally Long Cycle Time.

[0122] 7. Abnormally Low Yield.

[0123] As an example in connection with Part 4, Data Consistency BetweenSupplier and Buyer's Data, the following are checked:

[0124] 1. Date Sequence Error. For example, a downstream supplierreceived before the upstream supplier shipped.

[0125] 2. WIP Movement Error. For example, the same lot appears at twodifferent suppliers at the same time.

[0126] 3. Status Sequence Error

[0127] 4. Abnormal Long Cycle Time

[0128] 5. Shipped but Not Received

[0129] 6. Shipped Quantity Does Not Equal Received Quantity

[0130] As an example in connection with Part 5, Data Consistency BetweenSuppliers, the following are checked:

[0131] 1. Consistency Between Purchase Order and Work Order. Forexample, device and item no should be consistent; sum of work order costshould be equal or less than the blanket purchase order amount.

[0132] 2. Consistency Between WIP and Production Order. For example,Production Order No, Device, Item No, and Qty in WIP should match withthe production order information.

[0133] 3. Consistent Between DTR and Production Order. For example,production order no, device, item no, and qty in DTR should match withthe production order information.

[0134] 4. Consistency Between WIP and DTR. For example, the differencein WIP between the two consecutive dates should be equal to amountsshown in DTR.

[0135] 5. Consistency Between DTR and Shipment Report.

[0136] 6. Consistency Between DTR and Inventory. For example, theInventory report should be equal to the results obtained by thecumulative DTR.

[0137]FIG. 12 depicts one example of a multiple supplier branch in asupply chain transaction where after the Wafer Sort stage by suppliertesta, the Assembly stage for a lot is distributed to three suppliers,namely pkgk, pkgz and pkgftp.

[0138] In FIG. 12, the Raw Material is an input to the Fab stage atsupplierfabc and Lot No T0239A is assigned. When the Fab stage work iscomplete, a Wafer Shipping Notice is issued and the wafers are deliveredfor the Wafer Sort stage to supplier testa for the Lot No T0239A. Whenthe Wafer Sort stage work is complete, a Sorted Wafer Shipping Notice isissued and the scribed wafers are delivered for the Assembly stage toAssembly supplier pkgk with Lot No T0239A-1 assigned, are delivered forthe Assembly and Final Test stages to Assembly & Final Test supplierpkgz and Lot No T0239A-2 is assigned, and delivered for the Assembly andFinal Test stages to Assembly & Final Test supplier pkgftp and Lot NoT0239A-3 is assigned. When the Assembly supplier pkgk with Lot NoT0239A-1 completes the packaging, a Assembled Die Shipping Notice isissued and the packaged devices are delivered for the Final Test stageto the Final Test supplier pkgftp with Lot No T0239A-1 retained. Whenthe Final Test supplier pkgftp finishes the Final Test on Lot NoT0239A-1, the Finished Goods are available. When the Final Test supplierpkgz finishes the Final Test on Lot No T0239A-2, the Finished Goods areavailable. When the Final Test supplier pkgftp and finishes the FinalTest on Lot No T0239A-3, the Finished Goods are available.

[0139]FIG. 13 depicts cross supplier error checking in the example ofFIG. 12. The Wafer Sort stage supplier testa for the Lot No T0239A-2 hasan Out Date, indicated by 2* in FIG. 13, of Feb, 28, 2002 where thedesignated supplier is pkgz. The supplier pkgz for the Lot No T0239A-2,however, has an In Date, indicated by 2* in FIG. 13, of Jan 28, 2002which of course is an error since the goods could not have been receivedby pkgz before they were shipped by testa. This error is detected by theDATA INTEGRITY UNIT 88-6 of FIG. 11.

[0140] In FIG. 13, the Assembly stage supplier pkgk for the Lot NoT0239A-1 has a QTY/die Out quantity, indicated by 1 * in FIG. 13, of3200 where the designated supplier is pkgftp. The supplier pkgftp forthe Lot No T0239A-1, however, has a QTY/die In quantity, indicated by 1*in FIG. 13, of 4200 which of course is an error since more goods couldnot have been received by pkgftp then were shipped by pkgk. This erroris detected by the DATA INTEGRITY UNIT 88-6 of FIG. 11.

[0141]FIG. 14 depicts one example of a lot tracking report. Lot Trackingis executed by the BUSINESS LOGIC 98-2 of FIG. 10 to store detailedinformation related to a lot in the production supply chain. Theinformation tracked in the lot tracking has two categorizes as follows:

[0142] Category 1. Static Data: where the data are fixed during themanufacturing processes.

[0143] Category 2. Dynamic Data: where the data can be changed duringthe manufacturing processes.

[0144] The Static Data includes:

[0145] a) Lot number,

[0146] b) Part no,

[0147] c) Purchase order no,

[0148] d) Production order no,

[0149] e) Date code,

[0150] f) Supplier,

[0151] g) Routing,

[0152] h) Order date,

[0153] i) Order Qty,

[0154] j) Unit Price,

[0155] The Dynamic Data includes two main parts, namely, DateInformation and Qty Information where they have the following subparts:

[0156] a) Date Information:

[0157] 1) Received date

[0158] 2) Start date

[0159] 3) Hold date

[0160] 4) Completed date

[0161] 5) Ship date

[0162] b) Qty Information

[0163] 1) Received Qty

[0164] 2) Returned Qty

[0165] 3) Start Qty

[0166] 4) Hold Qty

[0167] 5) Completed Qty

[0168] 6) Good part Qty

[0169] 7) Scrap part Qty

[0170] 8) Downgrade Qty

[0171] 9) Ship Qty

[0172] Lot tracking records the flow of a lot by keeping its genealogyin order to track the lot history. These records include a parent-childrelationship for the unsplit lots and include a sibling relationship forsplit lots. Lot tracking information is loaded, for example, using WIPor DTR information. Lot tracking keeps a complete and consistent dataset for all the production and finance related information in onecentral place, that is, in the 97′-2 of FIG. 11. With this commonrepository of lot information for the entire supply chain, performancechecking (such as cycle time and yield analysis) and detailed costreports down to the lot details are provided supply chain managementsystem.

[0173] In lot tracking and as shown in the FIG. 14, the supply chainmanagement system assigns a Base Lot indicator number to every lot. InFIG. 14, that Base Lot number is N1805 and a Lot No related to the BaseLot number is also kept so that the routing to and local identificationfor each of the suppliers is recorded in the lot tracking information.The particular Base Lot number N1805 of FIG. 14 has a ROUTE that tracesthe sequence Fab at supplierfabc with Base Lot number N1805, Wafer Sortat supplier testa with Base Lot number N1805, Assembly at supplier pkgkwith Lot No N18058 and Final Test at supplier pkgftp with Lot NoN18058.1, with Lot No N18058.2 and with Lot No N18058.3.

[0174]FIG. 15 depicts a first cross supplier lot tracking example. InFIG. 15, the Raw Material is an input to the Fab stage at supplierfabcand Lot No N1805 is assigned. When work at the Fab stage is complete, aWafer Shipping Notice is issued and the wafers are delivered for theWafer Sort supplier testa for the Lot No N1805. When the Wafer Sortstage work is complete, a Sorted Wafer Shipping Notice is issued and thesorted wafers are delivered for the Assembly stage to Assembly supplierpkgk with Lot No N1805S assigned. When the Assembly supplier pkgk withLot No N1805S completes the packaging, an Assembled Die Shipping Noticeis issued and the packaged devices are delivered for the Final Teststage to the Final Test supplier pkgftp with Lot No N1805S.1, Lot NoN1805S.2 and Lot No N1805S.3 assigned. When the Final Test supplierpkgftp finishes the Final Test on Lot No N1805S.1, Lot No N1805S.2 andLot No N1805S.3, the Finished Goods are available for each of thoselots.

[0175]FIG. 16 depicts a second cross supplier lot tracking example. InFIG. 15, the Raw Material is an input to the Fab stage at supplierfabcand Lot No T0239A is assigned. When the Fab stage work is complete, aWafer Shipping Notice is issued and the wafers are delivered for theWafer Sort stage to supplier testa for the Lot No T0239A. When the WaferSort stage work is complete, a Sorted Wafer Shipping Notice is issuedand the sorted wafers are split into three orders and are delivered forthe Assembly stage to Assembly supplier pkgk with Lot No T0239A-1assigned, are delivered for the Assembly stage to Assembly supplier pkgzwith Lot No T0239A-2 assigned and are delivered for the Assembly stageto Assembly supplier pkgftp with Lot No T0239A-3 assigned. When theAssembly supplier pkgk with Lot No N1805S completes the packaging, aAssembled Die Shipping Notice is issued and the packaged devices aredelivered for the Final Test stage to the Final Test supplier pkgftpwith Lot No N1805S.1, Lot No N1805S.2 and Lot No N1805S.3 assigned. Whenthe Final Test supplier pkgftp finishes the Final Test on Lot NoN1805S.1, Lot No N1805S.2 and Lot No N1805S.3, the Finished Goods areavailable for each of those lots.

[0176]FIG. 17 depicts an Actual Cost—Lot Detail Report for the Lot NoN18005S.1 from Final Test Supplier pkgftp of FIG. 15. The ability of thesupply chain management system to run the FIG. 15 reports results fromthe Lot Tracking that is performed. In order to perform Lot Tracking,the mapping of fragmented information among multiple Suppliers isrequired. The accuracy of the report depends on the accuracy of theinformation and hence the data integrity processing is important toreport accuracy.

[0177]FIG. 18 depicts the purchase order logic flow for creation andacceptance of orders. Such orders are of the type described inconnection with FIG. 5, FIG. 6 and FIG. 7 where a buyer issues a set ofdependent purchase orders in order to progress Raw Materials to FinishedProduct. As a first step, a Buyer will initiate the process Buyer CreateBPO entry at A to create a blanket purchase order. The terms of the BPOare set and may be a standard contract with standard terms andconditions of the Buyer. Normally, the BPO undergoes one or mangerapprovals for the Buyer usually based upon price thresholds for eachmanager. The higher the price, the more management levels that may berequired. No Manager 1Approve? is required if the price is less than afirst threshold, Price ≦$T1, and a Yes results sending the BPO to theSupplier input C. If the BPO price is not less than a first threshold,Price ≦$T1, and a No results, a Manager1Approve? is required and if a Noresults, a return is made for further adjustment of the BPO. If aManager1Approve? is required and is Yes, the approval process continuesfor one or more additional approvals. For example, when noManager2Approve? is required (the price is less than a second threshold,Price ≦$T2) and a Yes results sending the BPO to the Supplier input C.If the BPO price is not less than a second threshold, Price ≦$T2, and aNo results, a Manager2Approve? is required and if a No results, a returnis made for further adjustment of the BPO. If a Manager2Approve? isrequired and is Yes, the approval process continues for one or moreadditional approvals. Assuming Manager2Approve? is the last required anda Yes results sending the BPO to the Supplier input C.

[0178] If a BPO exists, or in the absence of a BPO if one is not to beused, a Buyer from time to time will initiate the process Buyer CreatePO entering at B to create a purchase order. The terms of the PO are setand may be a standard contract with standard terms and conditions underthe BPO of the Buyer or otherwise. As a first step, a Conditions OK?check is made to make sure that conditions are properly established forthe PO. If the current PO is dependent upon the output of another stage,perhaps from a different Supplier, the conditions precedent for the POare checked and if satisfied, a Yes will forward to a Terms OK? checkand if not a No will return to PO for further processing. As a secondstep, a Terms OK? check is made to make sure that terms of the PO arecorrect. For example, if the PO is under a BPO, then a check istypically made to determine if the quantity and cost is within thebalance remaining on the BPO. If the terms for the PO are checked and ifsatisfied, a Yes will forward to a Terms Adjust where, for example, theamount of the current PO will decrement the balance remaining on theBPO. If the Terms OK? check is not satisfactory, a No will return to POfor further processing. Normally, the PO undergoes one manger approvalManager0 Approve? and if a Yes results, the processing is sent to theSupplier input C and if No, a .process is sent to PO for furtherprocessing of the PO

[0179] When a Supplier receives a Supplier Accept BPO/PO input, enteringat C to create approval of a Buyer purchase order. The terms of the POare set and may be a standard contract with standard terms andconditions under the BPO of the Buyer or otherwise. As a first step, aBPO Terms OK? check is made to make sure that terms are properlyestablished for the PO or BPO. If the terms of the BPO are OK, a Yeswill forward to a Terms OK? check and if not a No will return to BPO/POfor further processing. As a second step, a PO Terms OK? check is maketo make sure that the terms of the PO are correct and if Yes willforward processing for manager approval. If the Terms OK? check is notsatisfactory, a No will return to BPO/PO for further processing.Normally, the PO undergoes one manger approval Manager Approve? and if aYes results, the processing terminates with Order Confirmed.

[0180]FIG. 19 depicts an example of Final Test Purchase Order. The PO ofFIG. 19 is in an on-line form to Supplier pkgftp and includes in thelower right-hand corner a thumbnail image of an attachment that detailscertain aspects of the PO. The ability of the supply chain managementsystem to run reports of the FIG. 19 type relies upon the Lot Trackingfacility. In order to perform Lot Tracking, the supply chain managementsystem maps fragmented information that inherently is fragmented amongmultiple Suppliers since there is no agreed upon standard in theindustry. As described, the local information for each client (Buyersand Suppliers) is mapped with reference to a master table thatconstitutes a super set of all the local tables for each of the clients.The accuracy of each report depends on the accuracy of the mappedinformation and hence the data integrity processing is important inorder to be able to have reporting accuracy among multiple Suppliers andamong multiple Buyers and multiple Suppliers.

[0181]FIG. 20 depicts an example of the attachment that appears as athumbnail image in the Final Test Purchase Order of FIG. 19.

[0182]FIG. 21 depicts an example of a Wafer Rolling Output Report. . Theability of the supply chain management system to run reports of the FIG.21 type relies upon the Lot Tracking facility. In order to perform LotTracking, the supply chain management system maps fragmented informationthat inherently is fragmented among multiple Suppliers since there is noagreed upon standard in the industry. As described, the localinformation for each client (Buyers and Suppliers) is mapped withreference to a master table that constitutes a super set of all thelocal tables for each of the clients. The accuracy of each reportdepends on the accuracy of the mapped information and hence the dataintegrity processing is important in order to be able to have reportingaccuracy among multiple Suppliers and among multiple Buyers and multipleSuppliers.

[0183]FIG. 22 depict an example a Finished Goods Rolling Output Report.. The ability of the supply chain management system to run reports ofthe FIG. 22 type relies upon the Lot Tracking facility. In order toperform Lot Tracking, the supply chain management system maps fragmentedinformation that inherently is fragmented among multiple Suppliers sincethere is no agreed upon standard in the industry. As described, thelocal information for each client (Buyers and Suppliers) is mapped withreference to a master table that constitutes a super set of all thelocal tables for each of the clients. The accuracy of each reportdepends on the accuracy of the mapped information and hence the dataintegrity processing is important in order to be able to have reportingaccuracy among multiple Suppliers and among multiple Buyers and multipleSuppliers.

[0184]FIG. 23 depicts an example a Work in Progress Inventory Report.The ability of the supply chain management system to run reports of theFIG. 23 type relies upon the Lot Tracking facility. In order to performLot Tracking, the supply chain management system maps fragmentedinformation that inherently is fragmented among multiple Suppliers sincethere is no agreed upon standard in the industry. As described, thelocal information for each client (Buyers and Suppliers) is mapped withreference to a master table that constitutes a super set of all thelocal tables for each of the clients. The accuracy of each reportdepends on the accuracy of the mapped information and hence the dataintegrity processing is important in order to be able to have reportingaccuracy among multiple Suppliers and among multiple Buyers and multipleSuppliers.

[0185] In the supply chain management system, an alert process isprovided that extends across the multiple Suppliers environment and themultiple Buyers and multiple Suppliers environment. Typically, a Buyerhaving an integrated circuit (IC) design relies upon ProductionEngineers, Production Control Engineers or other Production Control (PC)personnel to find problems and exceptions that require action orcorrection during manufacture and procurement. Procurement from amanufacturing supply chain having multiple dependent suppliers, that is,where the output from one Supplier is the input for other Suppliers, hasincreased complexity when compared with less interdependent supplychains. If a Buyer can only use the Finished Product to solve problems,the job is tedious and error prone. The alert function is robust andextends to all stages in the supply chain. The alert function as one ofthe supply chain management functions greatly enhances problemidentification and correction in the supply chain.

[0186] The supply chain management system performs alert processes basedupon alert conditions for specific events/reports/process. The alertconditions are selected by clients. Alert reports are accessible toclients through onscreen operations or through other i-commerce methodsof communication. Typically, alert conditions are communicated daily (ormore frequently if desired) from the supply chain management system toclients in the form of event generation and alert messages.

[0187] By way of an example for the alert functions, it is assumed forpurposes of explanation that for a particular part (PROD), in theprocess of P, the standard production cycle time is X days. Theproduction control (PC) personnel, or production control (PC) agent ifan automated computer system, of a client specifies that if the realcycle time is longer than the standard cycle time by Y days, the clientis to be alerted. The supply chain management system implements thealgorithm as follows in TABLE 6: TABLE 6 Store info by PROD, P, X(static info) Store info by PC, Y (Client dependent) Periodically checkthe rule (for example, each time a production report enters the supplychain management system) as follows: If report has product PROD Ifreport is for process P If reported completion time − start time > XStore this record into Cycle > stdCycleTime With CycleTime = completiontime − start time With product = PROD With process = p When client (PC)accesses report, If client is PC List any existing records instdCycleTime Where product = PROD AND process = p AND CycleTime > Y.

[0188] The implementation of TABLE 6 is suitable for both standardreports and client preferences for improved performance.

[0189] Alerts are divided into categories:

[0190] 1) Abnormal time lapse:

[0191] a. Long Queue-in Time: The Queue-in Time is the period fromreceiving material (Received Date) to the start of the production (StartDate). A Long Queue-in Time is when the Queue-in Time is longer than aspecified period. Usually a Long Queue-in Time results from a constraintin production capacity or a delay in paper work.

[0192] b. Long In-process Time: The In-process Time is the amount oftime in a production process, WIP, and a Long In-process Time is whenthe In-process Time is taking an abnormally long time. A Buyer or otherclient may define a threshold for ‘long cycle time’ (per routing stage)and the supply chain management system reports any active WIP beyond thespecified threshold as a Long In-process Time.

[0193] c. Long On-hold Time: The On-hold Time is time when a productionprocess, WIP, is put on hold due to a quality issue, a machine setupproblem, a buyer request or other reason. A Buyer or other client maydefine a threshold for ‘long hold time’ (per routing stage) and thesupply chain management system reports any active WIP beyond thespecified threshold as a Long On-hold Time.

[0194] d. Long In-house Warehouse Time: During and after the productionprocess, WIP, the materials or finished goods are usually put in thesupplier's warehouse for temporary storage. This storage is calledIn-house Warehouse Time (also Die/Wafer bank time). A Long In-houseWarehouse Time is when the In-house Warehouse Time is too long. A Buyeror other client may define a threshold for ‘long in-house warehousetime’ and the supply chain management system reports any storage beyondthe specified threshold as a Long In-house Warehouse Time.

[0195] e. Long In-transit Time: The In-transit Time is the time lapsebetween the shipping of one supplier to the receiving of the followingsupplier. In-transit goods and materials generally are the mostdifficult to track in a supply chain. A Buyer or other client may definea threshold for ‘in-transit time’ and the supply chain management systemreports any storage beyond the specified threshold as a Long In-transitTime. The supply chain management keeps a log of how long it takes fromshipping to receiving at each stage.

[0196] f. Early Complete Notice—An early warning (x-days before theestimated completion date) is provided to enable a PC to start planningthe production flow. This feature is important for Fab and Wafer Sortstages.

[0197] g. Stationary Lot Report—A log to show lot movement during agiven period.

[0198] 2) Abnormal yield

[0199] a. Low Yield Threshold is defined by the Buyer or other client.The supply chain management system tracks yield down to per device, perpart number, per supplier and identifies low yield.

[0200] b. Excess Yield Threshold. Sometimes, a supplier reports theoutput quantity larger than reasonable, such as greater than the inputquantity causing a yield greater than 100%.

[0201] 3) Order and invoice

[0202] a. Missing PO. When material is set aside for a manufacturingprocess, the accompanying PO has to be there for suppliers to start thework. However, this is not always done. The supply chain managementsystem generates alerts for PC in these cases. The trigger can be set inany stage of the production flow: for example, when the upstream processis completed, or when the upstream production is shipped, or when thematerial is received.

[0203] b. Cost Approval Delay. When the production process is finished,the cost needs to be calculated and approved by PCs. If the costcalculation and approval process has too great a delay, it is difficultfor PC to reconcile this info with the real production data, since ithas been done a long time ago. The supply chain management system bringsthe cost calculation and approval process to alert the PC as soon as aparticular process is done, it can reduce the future dispute and controlthe production cost.

[0204] c. Cost Deviation. If the unit cost of a particular unit islarger than a particular percentage of the standard cost for such unit,the supply chain management system will bring alert the PC, it caneither be due to a low yield, or due to high unit cost.

[0205] d. Received but PO Not Issued—Lot received but PO has not beenissued.

[0206] e. Shipped but PO for next Stage Not Issued—Lot shipped but POhas not been issued for the following supplier.

[0207] f. Completed but PO Not Closed—WIP status is completed and PO isnot closed.

[0208] g. Completed but Invoice Not Approved—WIP status is completed,invoice is received and waiting for approval.

[0209] h. Wip Quantity Larger than Ordered Quantity—WIP quantity shouldbe equal or less than order quantity, this check is particularlyimportant for foundry PO/WIP reconciliation.

[0210] 4) Performance Index (After the production is done):

[0211] a. Yield Report—per device, part number, routing and supplier.

[0212] b. Cycle Time Report—per device, part number, routing andsupplier.

[0213] The supply chain management system employs planning based uponupstream visibility in the supply chain. Such capabilities areparticularly useful in outsourcing to suppliers in a semiconductorsupply chain. In the semiconductor IC-design outsourcing industry, thebuyer (IC-design house) deals with multiple suppliers that providevarious outsourcing functions at different supplier stages. The buyerplaces a separate order (Purchase Order) with each supplier. Althoughthe Purchase Orders are separate between a buyer and each supplier, eachsupplier depends on the previous supplier (upstream supplier) in thesupply chain. In order to procure a chip as finished goods, a buyerfirst orders wafers from a Fab supplier (foundry); once the work at theFab supplier is finished, the buyer orders sorting from a Wafer Sortsupplier; after the Wafer Sort work is finished, the buyer ordersAssembly from an Assembly supplier; and finally, the buyer orders FinalTest from a Final Test supplier. The supply chain management system, forexample, is able to perform group order generation for groups ofdependent suppliers (Fab, Wafer Sort, Assembly and Final Test suppliers)in the supply chain.

[0214] At each step of the supply chain, a downstream supplier waits forthe previous upstream supplier to complete (or partially complete) itswork before commencement of work under a new order can begin. The supplychain management system allows the buyer to create virtual downstreamorders once upstream orders are underway. The supply chain managementsystem uses estimated date (and continuously update as more up to dateinfo is provided with the WIP data), to create virtual (future) ordersfor the downstream suppliers.

[0215] Besides providing the buyer with order creation, the supply chainmanagement system also provides the suppliers with up to dateinformation regarding up coming orders. Downstream suppliers can use thesupply chain management system to view the current status of thematerials, which will eventually be arriving and requiring theirservices.

[0216] In an example for describing the operation, a buyer has arequirement for final goods (FG) of amount Q chips on date D. Based uponthis information, the supply chain management system operates as in thefollowing TABLE 7: TABLE 7 Calculate the initial wafer required: UsingBill of Routing: FG is made from FT-FG in Final Test with standard yieldYft, standard cycle time Dft, by supplier Sft, Thus the date andquantity to start FT is: Q-FT = Q / Yft FTD = D - Dft FT-FG is made fromAS-FG in Assembly with standard yield Yas, standard cycle time Das, bysupplier Sas, Thus the date and quantity to start AS is: Q-AS = Q-FT /Yas = Q / Yft / Yas ASD = FTD - Das = D - Dft - Das AS-FG is made fromWS-FG in Wafer Sort with standard yield Yws, standard cycle time Dws, bysupplier Sws, Q-WS = Q-AS / Yws = Q / Yft / Yas / Yws WSD = ASD - Dws =D - Dft - Das - Dws WS-FG is made from FD-FG in Foundry, with wafer todie ratio W2D, with standard cycle time Dfd, by supplier Sfd, Thus thedate and quantity to start FD is: Q-FD = Q-WS / W2D = Q / Yft / Yas /Yws / W2D FDD = WSD - Dfd = D - Dft - Das - Dws - Dfd (for each lotthere are 25 wafers) QL-FD = Q-FD / 25

[0217] According to TABLE 6, the supply chain management system willgenerate orders for each of the suppliers with the proper quantity andrequired date (WS/AS/FT work orders are lot based).

[0218] Since the supply chain management system is connected to thesupply chain management system Lot Tracking engine, which keeps track onall the WIP data, the supply chain management system will constantlyupdate the Quantity and Date information in each of the subsequentorders.

[0219] Once those orders are generated, the buyer will be notified a fewdays (user specified) before the next order is needed to be submitted tothe supplier. The user can then come to the supply chain managementsystem and reconfirm the order and submit it. The entire process isautomatic and accurate, and greatly increases the productivity of PCpersonnel of the IC-design company.

[0220] While the invention has been particularly shown and describedwith reference to preferred embodiments thereof it will be understood bythose skilled in the art that various changes in form and details may bemade therein without departing from the scope of the invention.

1. (Original) A supply chain management system for clients that includeone or more buyers and a plurality of suppliers where said one or morebuyers place orders with a plurality of said suppliers for theprocessing of an input to an output, wherein said input is one or morelots, through a plurality of supplier stages where said clients each usefragmented different local information particular to each of saidclients, the improvement characterized by, a database store for storinglocal information for each of said clients, correlating means forcorrelating the local information with mapped data among said clientsand forming master information, said correlating means including one ormore base lot indicators, one for each of said one or more lots, used incommon for all of said stages, logic means for executing supply chainmanagement functions for tracking said lots through said supplier stagesusing said base lot indicators, said logic means including means forcreating a set of purchase orders to a group of said suppliers forprocessing the same lot where the creation of purchase orders fordownstream suppliers is dynamically conditioned on the outputs ofupstream suppliers.
 2. (Original) A supply chain management system forclients where the clients include a plurality of buyers and a pluralityof suppliers, where said buyers place orders with a plurality ofsuppliers for the processing of an input to an output through aplurality of supplier stages, said clients each using fragmenteddifferent local information particular to each of said clients, theimprovement characterized by, network communication means forinterconnecting said clients for maintaining said local informationcurrent in said supply chain management system, a database store forstoring master information in one or more tables having masterinformation correlated to local information, global processing means forprocessing supply chain management information for all of said clientsincluding, correlation means for correlating said local informationamong said clients, said correlation means including, input mappingmeans for mapping said local information for each of said clients asmapped data to provide master information for storage in said databasestore, said mapping means using base lot indicators, one for each ofsaid one or more lots, in common for all of said stages, logic means forexecuting supply chain management functions for tracking said lotsthrough said supplier stages using said base lot indicators, said logicmeans including means for creating a set of purchase orders to a groupof said suppliers for processing the same lot through a supply chainwhere the creation of purchase orders for downstream suppliers isdynamically conditioned on the outputs of upstream suppliers, said logicmeans accessing the master information for executing supply chainmanagement functions for tracking said lots through said supplier stagesand providing management data for creation of ones of said set ofpurchase orders, output mapping means for mapping said management datainto local data for said clients.
 3. (Original) The system as in eitherone of claims 1 and claims 2 including means for connecting with clientsthrough the Internet.
 4. (Original) The system as in either one ofclaims 1 and 2 including tables storing correlations between said masterinformation and said local information for each of said clients. 5.(Original) The system as in either one of claims 1 and 2 wherein saidcorrelation means includes data integrity means having data checkingmeans for detecting errors in said mapped data.
 6. (Original) The systemas in either one of claims 1 and 2 wherein said correlation meansincludes data integrity means having data cleansing means for correctingerrors in said mapped data.
 7. (Original) The system as in either one ofclaims 1 and 2 wherein said input is a lot.
 8. (Original) The system asin either one of claims 1 and 2 wherein said input is a lot and said lotis split at any one of said stages to two or more different stagesperforming the same type of processing.
 9. (Original) The system as ineither one of claims 1 and 2 wherein said input is lots and wherein saidlots, at any two or more of said stages performing the same type ofprocessing, are combined for processing in a downstream stage. 10.(Original) The system as in either one of claims 1 and 2 whereinsuppliers supply local supplier information via electronic records. 11.(Original) The system as in either one of claims 1 and 2 whereinsuppliers supply local supplier information to said system via data inelectronic records and reports and wherein said correlation meansincludes data integrity means that operates to check for dataconsistency within records, data consistency within reports, dataconsistency across different reports from a particular supplier, dataconsistency among data from multiple suppliers and one or more buyers,data consistency among data from multiple suppliers.
 12. (Original) Thesystem as in either one of claims 1 and 2 wherein said clients are inthe semiconductor manufacturing industry and said supplier stagesinclude one or more of Fab, Wafer Sort, Assembly and Final Test forprocessing from the input to the output.
 13. (Original) The system ofclaim 12 wherein said supplier stages include Fab, Wafer Sort, Assemblyand Final Test and one or more additional stages.
 14. (Original) Thesystem of claim 13 wherein said one or more additional stages includeone or more of Packaging, Bumping and Marking.
 15. (Original) The systemof claim 12 wherein said input is a lot.
 16. (Original) The system ofclaim 12 wherein said input is a wafer lot.
 17. (Original) The system ofclaim 12 wherein said input is a die lot.
 18. (Original) The system ofclaim 12 wherein said output is finished goods.
 19. (Original) Thesystem of claim 12 wherein said output is dies.
 20. (Original) Thesystem as in either one of claims 1 and 2 wherein said input includes aplurality of lots, wherein said database stores one or more tables forcorrelations between said master information and said local informationfor each of said buyers and suppliers for each of said lots and whereineach of said tables has unique ones of said base lot indicators commonto all tables for identifying said lots.
 21. (Original) The system as ineither one of claims 1 and 2 wherein said input includes a plurality oflots, wherein said database stores one or more tables for correlationsbetween said master information and said local information for each ofsaid buyers and suppliers for each of said lots and wherein each of saidtables has unique ones of said base lot indicators common to all tablesfor identifying said lots and wherein each of said stages has anadditional lot number for each base lot indicator whereby thecombination of said base lot indicator and the lot number represents thegenealogy of said lots in said stages.
 22. (Original) The system as ineither one of claims 1 and 2 wherein said input is a lot, wherein saiddatabase stores one or more tables for correlations between said masterinformation and said local information for each of said buyers andsuppliers and wherein each of said tables has a base lot indicatorcommon to all tables for identifying said lot.
 23. (Original) The systemof claim 22 wherein said local information is RosettaNet information.24. (Original) The system of claim 22 wherein said clients are in thesemiconductor manufacturing industry and said supplier stages for eachlot include one or more of Fab, Wafer Sort, Assembly and Final Test. 25.(Original) The system of claim 22 wherein said supplier stages for oneor more of said lots is split among multiple Fab stages.
 26. (Original)The system of claim 22 wherein said supplier stages for one or more ofsaid wafer lots is split among multiple Wafer Sort stages. 27.(Original) The system of claim 22 wherein said supplier stages for oneor more of said wafer lots are split among multiple Assembly stages. 28.(Original) The system of claim 22 wherein said supplier stages for oneor more of said wafer lots is split among multiple Final Test stages.29. (Original) The system as in either one of claims 1 and 2 whereinsaid clients are in the semiconductor manufacturing industry and saidinput is a wafer lot and wherein said supply chain management functionsprovide a lot tracking report based upon said lot data.
 30. (Original)The system of claim 29 wherein said lot data is static data. 31.(Original) The system of claim 30 wherein said static data includes DateCode, Lot No, Order Date, Order Qty, PO No, Routing, Sup, and UnitPrice.
 32. (Original) The system of claim 29 wherein said lot data isdynamic data.
 33. (Original) The system of claim 32 wherein said dynamicdata includes Date Information and Quantity Information.
 34. (Original)The system of claim 33 wherein said Date Information includes CompletedDate, Hold Date, Received Date, Ship Date and Start Date.
 35. (Original)The system of claim 33 wherein said Quantity Information includes andCompleted Qty, Hold Qty, Received Qty, Ship Qty and Start Qty. 36.(Original) The system as in either one of claims 1 and 2 wherein saidclients are in the semiconductor manufacturing industry and said inputis a wafer lot and said output is a chip product and wherein said supplychain management functions include an actual cost lot detail report. 37.(Original) The system as in either one of claims 1 and 2 wherein saidclients are in the semiconductor manufacturing industry and said inputis a wafer lot and said output is a chip product and wherein said supplychain management functions include a wafer rolling output report. 38.(Original) The system as in either one of claims 1 and 2 wherein saidclients are in the semiconductor manufacturing industry and said inputis a wafer lot and said output is a chip product and wherein said supplychain management functions include a finished goods rolling outputreport.
 39. (Original) The system as in either one of claims 1 and 2wherein said clients are in the semiconductor manufacturing industry andsaid input is a wafer lot and said output is a chip product and whereinsaid supply chain management functions include a work in progressinventory report.
 40. (Original) The system as in either one of claims 1and 2 wherein said clients are in the semiconductor manufacturingindustry and said input is a wafer lot and said output is a chip productand wherein said supply chain management system functions to include analert to signal a condition in the supply chain management system. 41.(Original) The system as in either one of claims 1 and 2 wherein, saidbuyers, B, include buyers B₀, B₁, . . . , B_(b), . . . , B_(B), saidsuppliers, S, include suppliers So, S₁, . . . S_(S), . . . ,S_(S), saidstages, P, include stages [P_(0,0), P_(0,1), . . . . , P_(0,N)];[P_(1,0), . . . ]; [ . . . P_(m,n), . . . ]; [P_(M,0), . . . , P_(M,N)].42. (Original) The system of claim 41 wherein each of said stages, P,includes up to T transactions, T₀, T₁, . . . , T_(T).
 43. (Original) Thesystem of claim 42 wherein said T transactions are ORDER, WIP, YIELD,SHIPMENT, RECEIVE, WAREHOUSE and PAYMENT.
 44. (Original) A method ofchain management for clients that include one or more buyers and aplurality of suppliers where said one or more buyers place orders with aplurality of said suppliers for the processing of an input to an output,wherein said input is one or more lots, through a plurality of supplierstages where said clients each use fragmented different localinformation particular to each of said clients, the improvementcharacterized by, storing local information for each of said clients ina database store, correlating the local information with mapped dataamong said clients and forming master information, said correlatingmeans including one or more base lot indicators, one for each of saidone or more lots, used in common for all of said stages, executingsupply chain management functions for tracking said lots through saidsupplier stages using said base lot indicators.
 45. (Original) A methodof supply chain management for clients where the clients include one ormore buyers and a plurality of suppliers, where said one or more buyersplace orders with ones of said suppliers for the processing of an inputto an output through a plurality of supplier stages, said clients eachusing fragmented different local information particular to each of saidclients, the improvement characterized by, mapping said localinformation for each of said clients to provide mapped data, executingdata integrity processes on said mapped data to improve the reliabilityof said mapped data, processing said mapped data to provide processeddata, storing the mapped data and the processed data as masterinformation, accessing the master information to execute supply chainmanagement functions for said clients.